Maximizing slurry pump efficiency
The handling of Mining and Aggregate slurries is a very punishing application that can have a major impact on plant productivity and efficiency. As global demand and competition continue to grow, it is more important than ever for producers to find reliable partners with solutions focused on improving the bottom line.
CHALLENGE - Lowering the operating cost
For operators today, the primary slurry pump challenges are to minimize the total cost of ownership and to ensure uptime is maintained. There are many contributing factors to total ownership costs beyond the initial cost. Energy efficiency, throughput, wear life, and the cost of service and parts all contribute to the calculation. Most important of all is uptime. Premature pump failure can bring an entire plant to a halt resulting in production losses, which should be factored into the pump’s true cost.
Specifying the wrong pump or not optimizing pump performance will negatively impact energy and wear parts consumption; these inefficiencies and the associated costs compound over the life of the pump. Considering that over 90% of a pump’s cost is energy and wear parts usage, even small efficiency gains will quickly offset differences in the operating cost of the pump. Selecting the ideal pump for process conditions is critical for baseline efficiency, while specifying a pump that allows for periodic hydraulic and impeller adjustments to maintain Best Efficiency Point throughout the life cycle of the pump will provide further cost savings.
Maintenance and service costs, along with the uptime you get out of a pump will have a huge impact on the total cost of ownership. The base cost of parts and service has an obvious impact, while proximity and immediacy of technicians and parts can play an even more critical role, as slow deployment of resources will prolong downtime.
Metso supplies a total solution to slurry pump applications from consultative services, start up support, wrench-turning service and innovative product solutions optimized specifically for each customer’s application. From product selection and technical support to comprehensive service agreements, Metso is more than a vendor: we’re a partner in our customers’ success.
Metso products and services are designed to help you maximize efficiency and lower operating costs. Our decades of application experience and proprietary selection software PumpDim help customers select the best pump from our broad range of products. To maximize wear life and efficiency we consider factors including process medium, inlet velocity, particle size and other variables unique to each customer’s process. The result is a highly efficient pump manufactured with the most ideal materials of construction for each application.
Metso also helps customers minimize maintenance costs and maximize uptime through our strategically placed global service centers. Our service network offers responsive technical expertise and inventory that’s never too far away. We work with customers to proactively contain maintenance costs through thoughtful planning and training of on-site staff to periodically optimize impeller settings and improve hydraulic performance.
Metso PumpDimᵀᴹ and PumpDim Lite
PumpDimᵀᴹ for Windowsᵀᴹ is primarily a program for sizing and selecting Metso’s pumps. It can size a pump for a specified duty point or a pipe system, pumping clear water, viscous liquids or a suspension of solids in a liquid.
PumpDimᵀᴹ and PumpDim Lite, Features:
For settling slurries and manual calculations, Cave’s correlation is the most common method of allowing for the effects of solids on pump performance.
Later methods like the Metso method which include pump size effect are utilized when sizing softwares like PumpDimᵀᴹ are used. These methods are more accurate and the Cave method is often too conservative.
PumpDim Lite was recently launched as a web based subsidiary to Metso PumpDimᵀᴹ. PumpDim Lite is an advance selection application tool that can facilitate quick budgetary pump proposals and is compatiable on all internet accessible mobile devices.
PumpDim Lite only provides quick pump suggestions/proposals. For exact and applicable pump selections, the Metso PumpDim software should be used.
To obtain a better understanding of the pump sizing process, the inexperienced user is strongly recommended to study the booklet "Slurry Pump Basic" published by Metso Sweden AB.
Optimized to ensure maximum efficiency
Ensure safe and reliable operation with maximum time between failure
V-belt drive selection
Pipe system sizing
Pump performance with settling slurries
The results from PumpDimᵀᴹ are representative for settling slurries with “normal” particle size and distribution, such as those found in mineral processing industries, with concentrations lower than 40% by volume.
The program considers and/or calculates for example the following parameters:
Critical flow velocity to avoid settling of particles in pipes.
The complete pipe head loss system curve when static head, pipes, fittings and other components are specified.
Pumping of froth when a froth factor is specified.
Effect of solids on the generated pump head and pump efficiency.
Recommends material for the pump wet end considering particle size and distribution.
Selects pump size for the specified duty and calculates required pump speed.
Calculates shaft deflection and bearing life at the duty point.
Recommends motor size and drive for the duty.
Calculates slurry density based on particle and liquid density and concentration and/or tonnage. Calculates actual flow through an existing installation based on pipe system, slurry properties and pump speed i.e. determining circulating load in mill discharge applications.
Homogenous slurries with particles essentially smaller than 50 um i.e. clays, cement slurries, coating and filler quality calcium carbonates that have a non-Newtonian behaviour, need to be treated as a viscous liquid. The true slurry plastic dynamic viscosity, yield stress and flow index need to be known. These parameters can be established from test work carried out by Metso, or other laboratory.
For particles with a flaky or fibrous shape i.e. some mill scale applications and paper pulp applications need special considerations. Please consult Metso's application specialists.
A well-planned shutdown ensures reliability (Video)
Shutdown Success: Plan it well to ensure reliability
Driving OEE improvements - Implementing modern condition monitoring methods can have a real positive impact on Overall Equipment Effectiveness.
Condition monitoring is the science and practice of monitoring key information to alarm, predict and prevent problems. Familiar examples include the monitoring of tire pressure in your car, or monitoring the vibration of large motors in industrial facilities. Alerts and alarms provide some specific diagnostics that lead to a corrective action (i.e., for a car, pump the tyres with air), which leads to improved results and operation (i.e., fuel efficiency, reduced tyre wear, safer driving in wet weather).
The potential for improvement is great. Most industrial facilities are only leveraging a small fraction of the available process and equipment data, while many problems lie hidden in plain view. Large, expensive equipment can receive a lot of attention, while smaller, less expensive equipment is not monitored as closely. However, it should be, as up to 30% of control valves, for example, can improve process performance with minor repairs or upgrades.
Valve maintenance on its way to the cloud
For decades, process plants have been designed to be heavily automated to provide safe and stable operation. In general, plant operators have a good understanding of how a process plant operates but the feedback ARC has been receiving highlights the fact that it’s impossible for end users to be experts in everything.
60 years of industry-leading Neles valve solutions
Over the course of the past 60 years, the Neles product family has evolved from its strong roots in durable and reliable valves hardware to also include a comprehensive range of expert services and intelligent valve controller solutions. The youngest of our valve product families continues to actively look forward while leaning on Metso’s more than 90 years of valves experience. A lean way of operating driven by customer needs is how Metso has become, and will continue to be, a preferred valve solutions partner for all major industries worldwide.